Cladding

ABSTRACT

A clad structure and method of cladding a structure with horizontally extending, elongate supports, each support having an upper flange with a downwardly extending lip defining an open-bottomed groove and a lower flange with a tile retention protrusion along its upper surface. The tiles have upper flanges extending upwardly from their upper edge and ribs extending horizontally along a lower region of their rear surfaces. The upper flanges are positioned into the support groove during assembly and the ribs are retained behind the retention protrusions following assembly.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

The present invention is directed to methods and apparatus for claddingstructures to create a simulated tile or brick wall appearance.

Although framed buildings may be erected relatively cheaply and quicklyin comparison with buildings constructed using conventional brick-layingtechniques, the appearance of a conventional brick building is oftenpreferred. The present proposal concerns a method of simulating a brickwall, and may be employed to clad a wall of a framed building or otherstructure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a dimensioned vertical section through a tile support,

FIG. 2 is a dimensioned vertical section through a single tile used tosimulate a brick,

FIG. 3 is a vertical section through tiles supported on tile supports,

FIG. 3A is a view similar to FIG. 3 but showing a modified constructionof tile and tile support, and

FIG. 4 is a front elevation showing an array of tiles simulating a brickwall to illustrate pip spacing.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a tile support is formed by folding a metallicstrip into the cross-sectional shape shown. The strip may be formed fromaluminium, aluminium alloy or other suitable materials. Considering thestrip to extend horizontally with its horizontal centre lineperpendicular to the plane of the paper, it will be seen to have adownwardly inclined flange 3 along its upper edge and a horizontalflange 5 along its lower edge.

Both flanges extend from what will be regarded herein as the front sideof the support. The flange 3 terminates in a depending lip 4. The flange5 terminates in a depending hook-shaped profile 6, which defines achannel 8 opening upwardly on its rear side. The web 9 of the strip hasa horizontal score line 10 to facilitate drilling screw holes. Pips 12are pressed upwards from the flange 5 at intervals. At least one of theflanges is sprung relative to the web.

The support may be cut to the same length as the wall to be clad, or aplurality of supports may be arranged end to end.

A tile to be mounted on the support is of generally rectangular shape inelevation (as shown in FIG. 4). The tile may be manufactured from clay,cement or synthetic materials. Considering the tile to extendhorizontally with its horizontal centre line perpendicular to the planeof the paper, it has the vertical cross-sectional shape shown in FIG. 2.The main body portion 20 of the tile has a front surface 22 which isdimensioned to correspond to the major dimensions of the brick to besimulated. A first flange 24 extends upwardly from the body 20throughout the length of the tile with the front face of the flangespaced rearwardly from the tile face 22. The flange 24 terminates in anupper edge 25 and its rear surface is bevelled where it meets edge 25. Arib 26 extends horizontally the length of the rear side of the tile at aposition spaced from the lower edge of the tile equal to approximatelyone-third of the height of front face 22. The rib is shaped to define anundercut groove 28 in its lower surface. A groove 30 is defined betweenthe flange 24 and rib 26. The tile extends downwards from the rib 26 toterminate in a lower, horizontal edge 32. The rear faces of the flange24 and rib 26 lie in the same plane. It is not essential for the flange24 and rib 26 to extend the length of the tile and each may be ofdiscontinuous form, so as to constitute spaced ribs.

The preferred vertical cross-sectional dimensions of the tile and tilesupport are indicated in FIGS. 1 and 2 in millimetres purely by way ofexample. The horizontally extending edges of the tile are rounded andbevelled as shown to facilitate hanging.

Referring now to FIG. 3, a wall or other support surface is clad byfirst fixing to it rows of the tile supports shown in FIG. 1, one abovethe other, with the lip 4 of an upper support interfitting with thegroove 8 of the support immediately below it. Conveniently the supportsare fitted into place one after another by screws or bolts 40 screwedinto the wall and passed through holes drilled in the webs of thesupports along the line 10. After one support is fixed into place, thelip 4 is interfitted with the groove 8 of the next adjacent supportwhich is then similarly screwed or bolted into place, assuming that thesupports are fitted starting from the bottom of the wall. It is ofcourse possible to fix the supports in reverse order, starting at thetop of the wall and ending at the bottom.

The tiles may be fitted by offering up the flanges 24 of the lowest rowof tiles to the groove 42 defined by the profile 6 and web 9. The flange24 of each tile may be used to press the flange 3 upwards to allow thebottom of rib 26 to be moved past the pips 12 and bring the tiles intothe position shown in FIG. 3. In this position the head 41 of screw orbolt 40 is received within the groove 30, and the pips 12 are receivedwithin the groove 28 and restrain the tile against slipping out. Flange3 provides a spring force which presses the tile downwards. The adjacentrows of tiles are vertically spaced from one another by the conventionaldistance used in brick laying, as are the tiles in each row. The tilesdo not contact one another, but the body portion of each tile projectsdownwards so as to overlap the flange 24 of the tile or tilesimmediately below it and the overlying interfitting portions of thesupports. The gaps between the tiles may be pointed in the ordinary way.

Each of the pips 12 may have a length of 10 mm, and the inter-pipspacing may be selected to give the most suitable result. FIG. 4illustrates the relationship between tiles and pips at various differentpossible inter-pip spacings ranging from 50 mm to 115 mm, the optimumspacing being 95 mm. A greater spacing risks insufficient support forthe row of tiles, whereas lesser spacing involves unnecessary working ofthe strip. Instead of using pips to retain the tiles it is possible toprovide the flange 5 with a continuous bead, but this involves the riskof water accumulating behind the bead.

FIG. 3A is a view similar to FIG. 3 but showing modified tiles andstrips. In particular, the flange 24 is shorter and the lower edge 32 ofthe tile is closer to the rib 26 than in the case of the tile shown inFIGS. 2 and 3. In consequence, the lower edge 32 of each tile is atsubstantially the same level or slightly above the upper edges 25 of theflanges 24 of the tiles in the next adjacent tower row. This arrangementfacilitates removal and replacement of damaged tiles. To take account ofthe fact that there is a reduced gap between the groove 28 of each tileand the upper edges 33 of the tiles in the next adjacent lower row, thehook-shaped profiles 6 of the strips are also made shorter.

Compared with existing systems, the present invention provides asuperior method of simulating conventional brick walls. In particular,the invention provides the following advantages:

(a) a mechanical fixing for the tiles so as to eliminate weather-reliantprocesses such as bonding,

b) weather-proofing of the support surface prior to fixing of the tiles,

c) removability of individual tiles if damaged,

d) good impact-resistance as a result of the thickness of the tiles andtheir intimate contact with the support structure,

e) installation by unskilled labour because the tile supports areself-aligning and accurate measurements do not need to be taken, and

f) location of each tile within the tile support is independent of othertiles so that the system can accommodate the tolerances inherent in themanufacture of clay components.

Substantially the entire area of that part of the support surface to beclad with tiles is covered with the interlocking tile supports. Thisprocedure increases the speed at which a building may be clad. Moreover,because the supports are made from metal and interfit so as to leave noopenings through which water may penetrate, they cooperate to provide awaterproof shield within the tile cladding. The supports may be fixed bymeans other than screwing, for example by nailing, clipping or fixing toprojecting studs. Within the scope of the invention it is not essentialfor all of the tiles in a row to simulate bricks.

In an alternative construction, the upper edge of each tile support isunprofiled, and the lower edge is bent so as to form a flange and definethe pips 12 and the sprung portion 3, thereby to support and retain thelower edges of one row of tiles and retain the upper edges of anotherrow of tiles. The edge of the sprung portion bears against the upperedge of the adjacent strip to prevent water penetration. The upper edgesof the uppermost row of tiles may be retained by a separate retainingstrip.

What is claimed is:
 1. A clad structure including; a) a plurality ofelongate supports arranged one above another, each of said elongatesupports having; (i) a web which is secured to the structure, (ii)vertically spaced-apart flanges arranged along horizontal edges of theelongate support so as to project away from the structure, said flangesof each elongate support including; an upper flange (3) having adownwardly extending lip (4), and a lower flange (5) having a tileretention protrusion (12) on an upper surface, an edge of the lowerflange being turned upwards on a side nearer the web so as to have ahook-shaped profile (6) defining an open-topped channel (8); b) the lip(4) of the upper flange of one elongate support being received in theopen-topped channel (8) provided by the lower flange of the nextadjacent upper elongated support, so that the upper and lower flangesare interconnected and define an open-bottomed groove (42); c) and aplurality of tiles, each tile having; (i) a flange (24) projectingupwardly from an upper edge of the tile, which flange is spaced from afront surface of the tile, and (ii) a rib (26) on a rear surface of thetile, the rib being disposed in a lower region of the tile, saidupwardly projecting flange of the tile being received in saidopen-bottomed groove (42) and the rib being retained behind theprotrusion (12); and d) the plurality of tiles being secured to theplurality of elongate supports in rows with rows with tiles in rowsabove a lowest row being spaced from tiles in a row immediately below.2. A clad structure as claimed in claim 1, wherein the upper flange ofeach of the plurality of elongate supports has a downwardly inclinedportion which applies a spring force to a tile to press it downwards. 3.A clad structure as claimed in claim 2, wherein horizontal and verticaldimensions of front edges of each of the plurality of tiles correspondto those of conventional bricks.
 4. A clad structure as claimed in claim3, wherein gaps between the plurality of tiles are pointed.
 5. A cladstructure as claimed in claim 4, wherein a groove (30) is definedbetween the flange and rib provided on each tile, said groove receivinga head of a fixing means (40) securing the web to the structure.
 6. Aclad structure comprising; a) a plurality of elongate supports arrangedone above another, each of said elongate supports having; (i) a webwhich is secured to the structure, (ii) vertically spaced-apart flangesarranged along horizontal edges of the support so as to project awayfrom the structure, the flanges of each elongate support including, anupper flange defining with the web an open-bottomed groove, a lowerflange having a tile retention protrusion on its upper surface, (iii)one of said upper and lower flanges being shaped to define a channel, b)the plurality of elongate supports being secured to the structure with alip on a flange of one elongate support being received in the channeldefined by one of said upper and lower flanges of an adjacent elongatesupport so as to interconnect the flanges and prevent water penetration,c) a plurality of tiles, each tile having; (i) a flange projectingupwardly from an upper edge thereof, which flange is spaced from a frontsurface of the tile, and (ii) a rib on a rear surface of the tiledisposed in a lower region of the tile and spaced from a lower edgethereof; d) said upwardly projecting flange of each tile being receivedin the open bottomed groove and the rib being retained behind theprotrusion of one of said plurality of elongate supports, e) theplurality of tiles being mounted to the plurality of elongate supportsin rows such that tiles in rows above a lowest row are spaced from tilesin a row immediately below.
 7. A method of cladding a structure,comprising: a) providing a plurality of elongate supports each having aweb and upper and lower flanges projecting from longitudinal edges ofthe web, b) providing a plurality of tiles, each tile having a flange(24) projecting from one of its edges and a rib (26) on a rear side ofthe tile in a region of an opposite edge of the tile opposite to saidone edge, the rib being shaped to define an undercut groove (28) in aside of the rib nearer to said opposite edge of the tile, c) fixing thewebs of the plurality of elongate supports to the structure so that thesupports extend generally horizontally with the upper and lower flangesof the supports projecting away from the structure, the plurality ofelongate supports being so arranged that a downwardly extending lip (4)at an extremity of the upper flange of one of the plurality of elongatesupports is fitted into an open topped channel (8) defined by arearwardly upturned edge portion of the lower flange of a next adjacentupper one of said plurality of elongate supports so as to interconnectthe upper and lower flanges, d) fitting the plurality of tiles to theplurality of elongate supports, each of the plurality of tiles beingfitted to an elongate support with its said one edge uppermost byinserting the flange (24) of the tile into a groove (42) defined betweenthe web of the elongate support and interconnected flanges of theelongated support and an adjacent upper elongate support, and insertingthe rib (26) behind a tile retention protrusion on the lower flange,such that said protrusion is received in said undercut groove.